Transportation & Aviation

MAAS Aviation, Mobile, Ala.

MAAS Aviation operates a twin-bay paint shop for aircraft. Adjacent to its 18,000-square-foot hangars, 12,218 square feet of space houses offices and a mechanical area. In total, the facility is 48,319 square feet.

To achieve expansive clear spans, Haskell Corp., the design-builder, designed the facility with frames that run in the same direction as the purlins. The design features 285-foot continuous beam, flat-topped transverse frames. Each sequential frame is stepped down to create the roof slope. There is a series of 25- to 30-foot jack rafters that traverse the frames to support the purlins.

Varco Pruden Building’s metal building system was used for the project. A total of 360 tons of Rigid Frames and Continuous Beam framing was utilized. For secondary framing, Varco Pruden Buildings supplied 62.3 tons of G30 galvanized steel frames. Harrell Construction Co. Inc. was the furnish-and-erect contractor, and Downs Construction Co. LLC was the erector and installer.

The roof has 49,393 square feet of Varco Pruden Buildings’ 24-gauge Galvalume SSR roof system. Exterior walls are clad with 49,179 square feet of Varco Pruden Buildings’ 26-gauge, reverse-rolled Panel Rib Wall System coated in KXL Cool Arctic White and Cool Imperial Blue. By using reverse-rolled panel, the R-value of the insulation system was increased to R-19. Bay Insulation Systems Inc. supplied its vinyl reinforced blanket insulation for the roof and walls.

Inside the two hangars, 85,000 square feet of MBCI’s 24-gauge, factory-caulked FW-120 panels in Winter White line the ceiling and walls. The panels limit air penetration, which supports the paint shop’s quality control.

The metal building system was completed for $1,919,750 out of the project’s total cost of $22.4 million. MAAS Aviation’s project received a 2018 Varco Pruden Hall of Fame Award in the transportation category. It was completed in April 2017.